Methods of milling a piece of raw steel stock into a machine-ready piece of steel

ABSTRACT

A method of milling a piece of raw steel stock comprising: presenting a piece of raw steel stock having a first surface and a second surface having a perimeter; presenting a magnetic chuck with a top surface configured to support the piece of raw steel stock for milling with magnetic capabilities; arranging a minimum of four solid pole extensions on the top surface to support the second surface of the piece of raw steel stock for milling of the first surface thereof such that the solid pole extensions will be relatively evenly distributed beneath the perimeter of the second surface; arranging multiple mobile pole extensions on the top surface to further support the second surface; placing the second surface onto the multiple mobile pole extensions and the solid pole extensions; activating the magnetic capabilities of the magnetic chuck; and milling the first surface to a desired flatness.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims benefit to U.S. Provisional Application No.62/411,807, filed on Oct. 24, 2016, entitled “METHOD OF MACHINING FLAT,PARALLEL-SURFACED PLATE,” the disclosure of which is hereby incorporatedherein by reference in its entirety.

BACKGROUND OF THE INVENTION

A piece of raw steel stock typically is not ready to be machined. Thesides of the piece of raw steel stock are generally not flat enough norsufficiently parallel. Therefore, the sides of the piece of raw steelstock are ground down to become flat and parallel within specifiedtolerances.

Conventional methods of transforming a piece of raw steel stock down toa flat machine-ready piece suffer from many disadvantages. Theconventional methods typically include grinding, which uses ceramic andother abrasives. These grinding methods produce too much undesirableenvironmental waste, including thousands of tons of toxic sludge.Further, conventional methods take too long and are too expensive.

SUMMARY OF THE INVENTION

The inventor has discovered novel methods of milling a piece of rawsteel stock into a machine-ready piece of steel, depending on the sizeand shape of the piece of raw steel stock. The novel methods do notproduce environmental waste, are much quicker than conventional grindingmethods, and can produce machine-ready pieces of steel within muchtighter tolerance levels in terms of flatness and parallel-ness than theconventional grinding methods.

According to a first aspect of the disclosure, a method of milling apiece of raw steel stock down into to a machine-ready piece of steelcomprises: presenting a piece of raw metal steel having a first surfaceand a second surface on the opposite side as the first surface, thepiece of raw steel stock being at least 36 inches wide by 36 inches longand between ½ inch and 12 inches thick, and the second surface having aperimeter; presenting a magnetic chuck with a top surface configured tosupport the piece of raw steel stock for milling with magneticcapabilities (that is, with magnetic force); determining where on thetop surface of the magnetic chuck the second surface of the piece of rawsteel stock will be supported for milling of the first surface thereof;arranging a minimum of four solid pole extensions on the top surface tosupport the second surface of the piece of raw steel stock for millingof the first surface thereof such that the solid pole extensions will berelatively evenly distributed beneath the perimeter of the secondsurface of the piece of raw steel stock and within 2 inches of theperimeter; arranging multiple mobile pole extensions on the top surfaceto support the second surface of the piece of raw steel stock will besupported for milling; placing the second surface of the piece of rawsteel stock onto the multiple mobile pole extensions and the solid poleextensions; activating the magnetic capabilities of the magnetic chuck;and milling the first surface of the piece of raw steel stock to adesired flatness.

The first aspect of the invention can further include any one or more ofthe following features:

-   -   locating a bow in the piece of raw steel stock and arranging an        additional solid pole extension between the top surface and        where the bow in the piece of the raw steel stock will be        supported for milling;    -   milling with a face mill including a carbide cutting insert;    -   the face mill includes only one carbide cutting insert;    -   milling the first surface until the first surface has an        arithmetic mean surface roughness of 21 micrometers or less;    -   milling the first surface of the piece of raw steel stock        further includes milling the first surface of the piece of raw        steel stock to a flat surface within a tolerance of 0.001 inch        per 36 inches; and    -   removing the piece of raw steel stock after the milling of the        first surface thereof and repeating the steps described above to        mill the second surface of the piece of raw steel stock.

According to a second aspect of the disclosure, a method of milling apiece of raw steel stock down into to a machine-ready piece of steelcomprises: presenting a piece of raw steel stock having a first surface,a second surface on the opposite side as the first surface, and at leastone protrusion at least 5 inches in length; presenting a magnetic chuckwith a top surface configured to support the piece of raw steel stockfor milling via magnetic capabilities; determining where on the topsurface of the magnetic chuck the second surface of the piece of rawsteel stock will be supported for milling of the first surface thereof;arranging a minimum of four solid pole extensions on the top surface tosupport the second surface of the piece of raw steel stock for millingof the first surface thereof such that the solid pole extensions arerelatively evenly distributed under a perimeter of the piece of rawsteel stock and within 2 inches of the perimeter and at least one solidpole extension will be disposed under each of the at least oneprotrusions; arranging multiple mobile pole extensions on the topsurface to support the second surface of the piece of raw steel stockfor milling; placing the second surface of the piece of raw steel stockonto the multiple mobile pole extensions and the solid pole extensions;activating the magnetic capabilities of the magnetic chuck; and millingthe first surface of the piece of raw steel stock to a desired flatness.

The second aspect of the invention can further include any one or moreof the following features:

-   -   milling with a face mill including a carbide insert;    -   the face mill includes only one carbide insert;    -   milling the first surface until the first surface has an        arithmetic mean surface roughness of 21 micrometers or less;    -   milling the first surface of the piece of raw steel stock to a        flat surface within a tolerance of 0.001 inch per 36 inches;    -   locating a bow in the piece of raw steel stock and arranging an        additional solid pole extension between the top surface and        where the bow in the piece of the raw steel stock will be        supported for milling; and    -   removing the piece of raw steel stock after the milling of the        first surface thereof and repeating the steps described above to        mill the second surface of the piece of raw steel stock.

According to a third aspect of the disclosure, a method of milling apiece of raw steel stock down into to a machine-ready piece of steelcomprises: presenting a piece of raw steel stock having a first surface,a second surface on the opposite side as the first surface, and at twoholes extending from the first surface through to the second surface;presenting a magnetic chuck with a top surface configured to support thepiece of raw steel stock for milling via magnetic capabilities;determining where on the top surface of the magnetic chuck the secondsurface of the piece of raw steel stock will be supported for milling ofthe first surface thereof; arranging a minimum of four solid poleextensions on the top surface to support the second surface of the pieceof raw steel stock for milling of the first surface thereof such thatthe solid pole extensions will be relatively evenly distributed under aperimeter of the piece of raw steel stock and within 2 inches of theperimeter and at least one solid pole extension will be disposed betweenthe at least two holes; arranging multiple mobile pole extensions on thetop surface to support the second surface of the piece of raw steelstock for milling the first surface thereof; placing the second surfaceof the piece of raw steel stock onto the multiple mobile pole extensionsand the solid pole extensions; activating the magnetic capabilities ofthe magnetic chuck; and milling the first surface of the piece of rawsteel stock to a desired flatness.

The third aspect of the invention can further include any one or more ofthe following features:

-   -   milling with a face mill including a carbide insert;    -   the face mill includes only one carbide insert;    -   milling the first surface until the first surface has an        arithmetic mean surface roughness of 21 micrometers or less;    -   milling the first surface of the piece of raw steel stock to a        flat surface within a tolerance of 0.001 inch per 36 inches;    -   locating a bow in the piece of raw steel stock and arranging an        additional solid pole extension between the top surface and        where the bow in the piece of the raw steel stock will be        supported for milling; and    -   removing the piece of raw steel stock after the milling of the        first surface thereof and repeating the steps described above to        mill the second surface of the piece of raw steel stock.

These and other features, advantages, and objects of the presentinvention will be further understood and appreciated by those skilled inthe art by reference to the following specification, claims, andappended drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings:

FIG. 1A is a perspective view of a first embodiment of a piece of rawsteel stock, illustrating a first surface including edges formingcorners and a perimeter;

FIG. 1B is a perspective view of the first embodiment of a piece of rawsteel stock, illustrating a second surface including edges formingcorners and a perimeter;

FIG. 2 is a perspective view of a magnetic chuck to secure the piece ofraw steel stock of FIGS. 1A and 1B for milling, illustrating a grid oftop surface segments;

FIG. 3 is a perspective view of a solid pole extension, which can beplaced on a top surface segment of the magnetic chuck of FIG. 2 tosupport the piece of raw steel stock of FIGS. 1A and 1B for milling;

FIG. 4 is a perspective view of a mobile pole extension, which can beplaced on a top surface segment of the magnetic chuck of FIG. 2 tofurther support the piece of raw steel stock of FIGS. 1A and 1B formilling;

FIG. 5 is a perspective view of the magnetic chuck of FIG. 2 furtherillustrating an area of the top surface of the magnetic chuck on whichthe second surface of the piece of raw steel stock of FIGS. 1A and 1Bwill be supported for milling the first surface thereof;

FIG. 6 is a perspective view of the magnetic chuck of FIG. 2 furtherillustrating solid pole extensions relatively evenly distributed on thetop surface to support the perimeter of the second surface of piece ofraw steel stock of FIGS. 1A and 1B for milling the first surfacethereof;

FIG. 7 is a perspective view of the magnetic chuck of FIG. 2 furtherillustrating mobile pole extensions arranged on every other availabletop surface segment within the area corresponding to the perimeter ofthe second surface of the piece of raw steel stock of FIGS. 1A and 1B;

FIG. 8 is a perspective view of the magnetic chuck of FIG. 2 and thesolid pole extensions and mobile pole extensions supporting the secondsurface of the piece of raw steel stock of FIGS. 1A and 1B for millingof the first surface thereof;

FIG. 9 is a perspective view of a milling element milling the firstsurface of the piece of raw steel stock of FIGS. 1A and 1B, while beingsupported as illustrated in FIG. 8;

FIG. 10 is a perspective view of the bottom of the milling element ofFIG. 9, illustrating numerous spaces to hold a cutting insert but onlyincluding one cutting insert;

FIG. 11 is a perspective view of another piece of raw steel stock,otherwise identical to the piece of raw steel stock of FIGS. 1A and 1B,but further including a bow;

FIG. 12A is a perspective view of the magnetic chuck of FIG. 2,illustrating an area corresponding to a perimeter of a second surface ofthe piece of raw steel stock of FIG. 11 including an element identifyingwhere the bow will be supported and relatively evenly distributed solidpole extensions including a solid pole extension dedicated to supportthe bow;

FIG. 12B is a perspective view of FIG. 12A but also illustrating mobilepole extensions occupying every other available top surface segmentwithin the area;

FIG. 13 is a perspective view of another piece of raw steel stock,similar to the piece of raw steel stock of FIGS. 1A and 1B, but furtherincluding protrusions (tabs) extending from a lengthwise side and awidthwise side;

FIG. 14 is a perspective view of the magnetic chuck of FIG. 2,illustrating an area corresponding to where a perimeter of a secondsurface of the piece of raw steel stock of FIG. 13 will be supported formilling of a first surface thereof;

FIG. 15 is a perspective view of FIG. 14, further illustrating solidpole extensions arranged to support the perimeter of the second surfaceof the piece of raw steel stock of FIG. 13 and solid pole extensionsarranged to support each of the protrusions thereof;

FIG. 16 is a perspective view of FIG. 15, further illustrating mobilepole extensions arranged within the area to support the second surfaceof the piece of raw steel stock of FIG. 13 for milling the first surfacethereof;

FIG. 17 is a perspective view of another piece of raw steel stock,otherwise identical to the piece of raw steel stock of FIGS. 1A and 1B,but including a pair of holes extending from a first surface through toa second surface;

FIG. 18 is a perspective view of the magnetic chuck of FIG. 2,illustrating an area on the top surface thereof where the second surfaceof the piece of raw steel stock of FIG. 17 will be supported for millingof the first surface thereof;

FIG. 19 is a perspective view of FIG. 18 further illustrating solid poleextensions arranged to relatively evenly support the perimeter of thesecond surface of the piece of raw steel stock of FIG. 17 and a solidpole extension to support the second surface between the pair of holes;and

FIG. 20 is a perspective view of FIG. 19 further illustrating mobilepole extensions arranged within the area to support the second surfaceof the piece of raw steel stock of FIG. 13 for milling the first surfacethereof.

DETAILED DESCRIPTION

For purposes of description herein, the terms “under” and “beneath” andderivatives thereof shall relate to the disclosure as oriented in FIGS.8, 9, 12, 16, and 20. However, it is to be understood that thedisclosure may assume various alternative orientations, except whereexpressly specified to the contrary. It is also to be understood thatthe specific devices and processes illustrated in the attached drawings,and described in the following specification are simply exemplaryembodiments of the inventive concepts defined in the appended claims.Hence, specific dimensions and other physical characteristics relatingto the embodiments disclosed herein are not to be considered aslimiting, unless the claims expressly state otherwise.

Referring now to FIGS. 1A and 1B, a piece of raw steel stock 10 has afirst surface 12 and a second surface 14. The second surface 14 is onthe opposite side of the piece of raw steel stock 10 as the firstsurface 12. The piece of raw steel stock 10 is typically a slab of steelwith the first surface 12 and the second surface 14 that areapproximately flat and parallel but not within acceptable tolerances formachining purposes. A process of milling the piece of raw steel stock 10described herein will transform the piece of raw steel stock 10 into amachine-ready piece of steel, and is advantageous over conventionalgrinding processes to transform the piece of raw steel stock 10 into amachine-ready piece of steel. The piece of raw steel stock 10 has awidth 16 of at least 36 inches, a length 18 of at least 36 inches, andthickness 20 of between ½ inch and 12 inches or more. The second surface14 of the piece of raw steel stock 10 further includes a perimeter 22,which can be defined by edges 24, 26, 28, 30. The edges 24, 26, 28, 30form corners 32, 34, 36, 38. The edges 24, 26, 28, 30 have centers 40,42, 44, 46 respectively. In general terms, the perimeter 22 of thesecond surface 14 is the boundary of the second surface 14 that would besupported for milling of the first surface 12 as discussed below. Thefirst surface 12 of the piece of raw steel stock 10 likewise includes aperimeter 48, which can be defined by edges 50, 52, 54, 56. The edges50, 52, 54, 56 form corners 58, 60, 62, 64. The edges 50, 52, 54, 56have centers 66, 68, 70, 72 respectively.

Referring now to FIG. 2, a magnetic chuck 74 to magnetically secure thepiece of raw steel stock 10 for milling is illustrated. The magneticchuck 74 includes a top surface 76. The top surface 76 of the magneticchuck 74 can, as illustrated, include a grid 78 with rows and columnsforming top surface segments 80. The grid 78 of course could includemore or less than top surface segments 80 than that illustrated in FIG.2. The top surface segments 80 are flat and level and planar with eachother, forming a flat and level top surface 76, which is thus configuredto support the piece of raw steel stock 10 for milling. When magneticcapabilities of the magnetic chuck 74 are activated, magnetic forcesmaintain any metal piece in magnetic communication with the top surface76 at the metal piece's position thereon, as discussed further below.The magnetic chuck 74 therefore can be utilized to maintain the piece ofraw steel stock 10 in a static position during a milling process totransform the piece of raw steel stock 10 into a machine-ready piece ofsteel.

Referring now to FIG. 3, one or more solid pole extensions 82 can beutilized with the magnetic chuck 74 while performing the milling processon the piece of raw steel stock 10. Each solid pole extension 82 issized to be placed on a top surface segment 80 of the magnetic chuck 74.More particularly, each solid pole extension 82 can be a cube or otherthree-dimensional piece of metal with a central aperture 84 to allow afastener to fasten the solid pole extension 82 to a top surface segment80 of the magnetic chuck 74. The one or more solid pole extensions 82can be placed on the top surface 76 of the magnetic chuck 74 to supportthe piece of raw steel stock 10 and to separate the top surface 76 ofthe magnetic chuck 74 from the piece of raw steel stock 10 during themilling operation of the piece of raw steel stock 10. Each solid poleextension 82, as mentioned, is metal and thus transfers the magneticforces from the magnetic chuck 74 to the piece of raw steel stock 10.

Referring to FIG. 4, one or more mobile pole extensions 86 can beutilized with the magnetic chuck 74 and the one or more solid poleextensions 82 while performing the milling process on the piece of rawsteel stock 10. The mobile pole extension 86 is sized to be placed on atop surface segment 80 of the magnetic chuck 74. An internal spring (notillustrated) biases the top portion 88 of the mobile pole extension 86away from the top surface segment 80 of the magnetic chuck 74 on whichthe mobile pole extension 86 is placed. Therefore, when the piece of rawsteel stock 10 is placed, with the second surface 14 toward the topsurface 76 of the magnetic chuck 74, on both one or more solid poleextensions 82 and one or more mobile pole extensions 86, the solid poleextensions 82 support the piece of raw steel stock 10 over the topsurface 76 of the magnetic chuck 74 and the spring of each of the one ormore mobile pole extensions 86 biases the top portion 88 of each mobilepole extension 86 to contact the second surface 14 of the piece of rawsteel stock 10. When the magnetic capabilities of the magnetic chuck 74are activated, the position of the top portion 88 of each of the mobilepole extensions 86 lock into place, further supporting the piece of rawsteel stock 10 but matching the contour of the second surface 14 of thepiece of raw steel stock 10. The mobile pole extensions 86 help preventthe magnetic chuck 74 from fully counteracting any natural warp in thepiece of raw steel stock 10.

As further described herein, the magnetic chuck 74, the one or moresolid pole extensions 82, and one or more mobile pole extensions 86 areutilized in a novel method to grind the piece of raw steel stock 10 intoa machine-ready piece of steel. The method includes determining where,on the top surface 76 of the magnetic chuck 74, the second surface 14 ofthe piece of raw steel stock 10 will be supported for milling of thefirst surface 12 of the piece of raw steel stock 10. Referring now toFIG. 5, an area 90 on the top surface 76 of the magnetic chuck 74corresponding to the perimeter 22 of the second surface 14 of the pieceof raw steel stock 10 is illustrated. Area 90 is, thus, where the secondsurface 14 of the piece of raw steel stock 10 can be supported formilling of the first surface 12 of the piece of raw steel stock 10. Adifferently shaped perimeter 22 would, of course, result in adifferently shaped area 90.

The method further includes arranging a minimum of four solid poleextensions 82 on the magnetic chuck 74 where (e.g., in the area 90) thesecond surface 14 of the piece of raw steel stock 10 will be supportedfor milling of the first surface 12 thereof such that the solid poleextensions 82 will be relatively evenly distributed under the perimeter22 of the second surface 14 of the piece of raw steel stock 10 andwithin 2 inches of the perimeter 22. Referring now to FIG. 6, the area90 of the top surface 76 of the magnetic chuck 74 corresponding to theperimeter 22 of the second surface 14 of the piece of raw steel stock 10is identified. Four solid pole extensions 82 a-82 d are placed on topsurface segments 80 a-80 d respectively of the magnetic chuck 74. Thefour solid pole extensions 82 a-82 d are placed at the top surfacesegments 80 a-80 d that overlap with the perimeter 22 of the secondsurface 14 of the piece of the raw steel stock 10. The four solid poleextensions 82 a-82 d are relatively evenly distributed around the area90 and thus under the perimeter 22 of the second surface 14, with solidpole extensions 82 a-82 d being placed to support approximately thecenters 40, 42, 44, 46 of the edges 24, 26, 28, 30, respectively, of thesecond surface 14 of the piece of raw steel stock 10. The four solidpole extensions 82 a-82 d could alternatively be arranged to support thecorners 32, 34, 36, 38 of the second surface 14 of the piece of rawsteel stock 10, such as at top surface segments 80 e-80 h of themagnetic chuck 74.

The method further includes arranging multiple mobile pole extensions 86between the top surface 76 and where the second surface 14 of the pieceof raw steel stock 10 will be supported for milling of the first surface12 (i.e., area 90). Referring now to FIG. 7, mobile pole extensions 86are positioned on top surface segments 80 of the magnetic chuck 74.Every top surface segment 80 within the area 90 corresponding to theperimeter 22 of the second surface 14 that is not occupied by a solidpole extension 82 (such as solid pole extensions 82 a-82 d) can beoccupied by a mobile pole extension 86, as illustrated.

The method further includes placing the second surface 14 of the pieceof raw steel stock 10 onto the multiple mobile pole extensions 86 andthe solid pole extensions 82 a-82 d. Referring now to FIG. 8, the secondsurface 14 of the piece of raw steel stock 10 is over the top surface 76of the magnetic chuck 74, supported by the solid pole extensions 82 a-82d. As mentioned above, the spring in each of the mobile pole extensions86 biases the top portion 88 of each of the mobile pole extensions 86 tocontact the second surface 14 of the piece of raw steel stock 10. Afterthe magnetic capabilities of the magnetic chuck 74 are activated, thetop portion 88 of each of the mobile pole extensions 86 locks into placeand further supports the second surface 14 of the piece of raw steelstock 10.

The method further includes activating the magnetic capabilities of themagnetic chuck 74. Because of the magnetic forces that the magneticchuck 74 provides, the piece of raw steel stock 10 is maintained inplace for milling. The method further includes milling the first surface12 of the piece of raw steel stock 10 to a desired flatness. Referringnow to FIG. 9, a milling element 92 mills the first surface 12. Apreferred milling element 92 is a face mill, which is illustrated as themilling element 92 in FIGS. 9 and 10. Referring to FIG. 10, the millingelement 92 (here, a face mill) includes spaces 94 to hold cuttinginserts 96. The milling element 92 preferably includes only one cuttinginsert 96, which can be a carbide cutting insert. However, the millingelement 92 could include multiple cutting inserts 96, such as multiplecarbide cutting inserts. The milling element 92 can mill the firstsurface 12 of the piece of raw steel stock 10 until the first surface 12has an arithmetic mean surface roughness (“Ra”) of 21 micrometers orless. The Ra value can be determined by a profilometer, as known in theart. Further, the milling element 92 can mill the first surface 12 ofthe piece of raw steel stock 10 to a flat surface within a tolerance of0.001 inch per 36 inches.

Referring now to FIG. 11, another piece of raw steel stock 10A, which isotherwise identical to the piece of raw steel stock 10 of FIG. 1,includes a bow 98. The bow 98 illustrated is an upward, concave, bowrelative to the first surface 12. The method can further includelocating the upward bow 98 in the piece of raw steel stock 10A, whichcan be done by visual inspection. Generally speaking, the thinner thepiece of raw steel stock 10A is, the greater the likelihood of theexistence of a bow 98. For example, a piece of raw steel stock 10Agreater than 3 inches in height (thickness) will likely not have a bow98. However, a piece of raw steel stock 10A about ½ inch in height(thickness) will likely have an upward bow 98. As illustrated in FIGS.12A and 12B, the method can further include arranging an additionalsolid pole extension 82 e between the top surface 76 and where theupward bow 98 in the piece of raw steel stock 10A will be supported formilling. As the area 90 corresponds to the perimeter 22 of secondsurface 14 of the piece of raw steel stock 10, element 90 a correspondsto the location of the upward bow 98. The method is otherwise the sameas that described above, with the multiple mobile pole extensions 86being arranged, the second surface 14 of the piece of raw steel stock10A being placed on the mobile pole extensions 86 and the solid poleextensions 82 a-82 e, the magnetic capabilities of the magnetic chuck 74being activated, and the first surface 12 being ground.

The method can further include removing the piece of raw steel stock 10(or 10A) after the milling of the first surface 12 thereof. The methoddescribed above can then be completed again to mill the second surface14 of the piece of raw steel stock 10 (or 10A). In other words, themethod can further include determining where on the top surface 76 ofthe magnetic chuck 74 the first surface 12 of the piece of raw steelstock 10 (or 10A) will be supported for milling of the second surface 14of the piece of raw steel stock 10 (or 10A). This concept was describedabove in connection with FIG. 5. Because the perimeter 48 of the firstsurface 12 and the perimeter 22 of the second surface 14 are essentiallythe same in the illustrated example, area 90 on the top surface 76 ofthe magnetic chuck 74 can also correspond to perimeter 48 of the firstsurface 12. It should be understood, however, that if the perimeter 48of the first surface 12 was larger, smaller, or otherwise significantlydifferent than the perimeter 22 of the second surface 14, then adifferent area 90 would correspond to the perimeter 48.

The method further includes arranging a minimum of four solid poleextensions 82 a-82 d between the top surface 76 and where the firstsurface 12 of the piece of raw steel stock 10 (or 10A) will be supportedfor milling of the second surface 14 thereof such that the solid poleextensions 82 a-82 d are relatively evenly distributed around the area90 corresponding to the perimeter 48 of the first surface 12 of thepiece of raw steel stock 10 (or 10A) and within 2 inches of theperimeter 48. If a separate upward bow (not illustrated) is present,solid pole extension 82 e will be arranged to support the bow. Thearranging of the minimum of four solid pole extensions 82 a-82 d can bedone in the manner described above in connection with FIG. 6 for themilling of the first surface 12. It should be understood however, thatif the perimeter 48 of the first surface 12 was larger, smaller, orotherwise significantly different than the perimeter 22 of the secondsurface 14, then a different area 90 would correspond to the perimeter48, and the minimum of four solid pole extensions 82 a-82 d wouldpossibly be positioned at different top surface segments 80 than thatdescribed in connection with FIG. 6.

The method further includes arranging multiple mobile pole extensions 86between the top surface 76 and where the first surface 12 of the pieceof raw steel stock 10 (or 10A) will be supported for milling. Thearranging of the multiple mobile pole extensions 86 can be done in themanner described above in connection with FIG. 7 for milling of thefirst surface 12, such as to occupy every available top surface segmentwithin the area 90 not occupied by the solid pole extensions 82 a-82 d(and 82 e, if an upward bow is present).

The method further includes placing the first surface 12 of the piece ofraw steel stock 10 (or 10A) onto the multiple mobile pole extensions 86and the solid pole extensions 82 a-82 d (and 82 e if an upward bow ispresent), activating the magnetic capabilities of the magnetic chuck 74,and then milling the second surface 14 of the piece of raw steel stock10 (or 10A) to a desired flatness. These actions can be performed in themanner described above in connection with FIGS. 8 and 9 for milling ofthe first surface 12. Like the first surface 12, the milling element 92can mill the second surface 14 of the piece of raw steel stock 10 (or10A) until the second surface 14 has an arithmetic mean surfaceroughness of 21 micrometers or less and to a flat surface within atolerance of 0.001 inch per 36 inches, and parallel to the first surface12. It should be understood that an arithmetic mean surface roughness of21 micrometers or less need not be achieved in one milling session. Forexample, the first surface 12 may be milled according to the methodsdescribed herein to an arithmetic mean surface roughness of greater than21 micrometers, the piece of raw steel stock 10 (or 10A) removed andflipped over, the second surface 14 milled to an arithmetic mean surfaceroughness of greater than 21 micrometers, the piece of raw steel stock10 (or 10A) again removed and flipped over, the first surface 12 milledto an arithmetic mean surface roughness of 21 micrometers or less, thepiece of raw steel stock 10 (or 10A) again removed and flipped over, andthe second surface 14 milled to an arithmetic mean surface roughness of21 micrometers or less. The milling and flipping concept can be repeatedas many times as desired until the desired arithmetic mean surfaceroughness is achieved.

Referring now to FIG. 13, another piece of raw steel stock 10B, similarto the piece of raw steel stock 10, includes a first surface 12 and asecond surface 14. The piece of raw steel stock 10B further includeslengthwise sides 100, 102, widthwise sides 104, 106, four primarycorners 108, 110, 112, 114, and several protrusions 116 (tabs) at leastfive inches of length 118 along the widthwise side 106 and lengthwiseside 102, respectively. The piece of raw steel stock 10B furtherincludes a perimeter 22 defined by the second surface 14 and theperimeter 48 defined by the first surface 12. Described herein is anovel method of milling, with the magnetic chuck 74, the raw metal steel10B with at least one protrusion 116 at least 5 inches in length 118(such as protrusions 116). As before, the method includes determiningwhere on the top surface 76 of the magnetic chuck 74 the second surface14 of the piece of raw steel stock 10B will be supported for milling ofthe first surface 12 of the piece of raw steel stock 10B. Referring nowto FIG. 14, the area 90 on the top surface 76 of the magnetic chuck 74,corresponding to the perimeter 22 of the second surface 14 of the pieceof raw steel stock 10B, is identified and determined as where the secondsurface 14 of the piece of raw steel stock 10B will be supported formilling of the first surface 12 of the piece of raw steel stock 10B.

The method further includes arranging a minimum of four solid poleextensions 82 between the top surface 76 and where the second surface 14of the piece of raw steel stock 10B will be supported for milling of thefirst surface 12 thereof such that the solid pole extensions 82 f-82 iwill be relatively evenly distributed beneath a perimeter 22 of thesecond surface 14 of the piece of raw steel stock 10B and within 2inches of the perimeter 22 and solid pole extensions 82 j and 82 k willbe disposed under each of the at least one protrusions 116 to supportthe protrusions 116 during milling. Referring now to FIG. 15, the area90 of the top surface 76 corresponding to the perimeter 22 of the secondsurface 14 of the piece of raw steel stock 10B is illustrated. Foursolid pole extensions 82 f-82 i are placed on top surface segments 80g-80 j respectively of the magnetic chuck 74. The four solid poleextensions 82 f-82 i are placed at top surface segments 80 g-80 j thatwill support the perimeter 22 of the second surface 14 of the piece ofthe raw steel stock 10B, as indicated by area 90. The four solid poleextensions 82 f-82 i are relatively evenly distributed around the area90 to support the perimeter 22 of the second surface 14 of the piece ofthe raw steel stock 10B, with solid pole extensions 82 f-82 i beingplaced to support approximately the corners 108, 110, 112, and 114 ofthe piece of raw steel stock 10B, such as at top surface segments 80 g,80 h, 80 i, and 80 j, respectively, of the magnetic chuck 74. Solid poleextensions 82 j and 82 k are additionally placed at top surface segments80 k and 80 l to support the protrusions 116 of the piece of raw steelstock 10B.

The method further includes arranging multiple mobile pole extensions 86between the top surface 76 and where the second surface 14 of the pieceof raw steel stock 10B will be supported for milling of the firstsurface 12 (i.e., area 90). Referring now to FIG. 16, mobile poleextensions 86 are positioned on top surface segments 80 of the magneticchuck 74. Every top surface segment 80 within the area 90 correspondingto the perimeter 22 of the second surface 14 that is not occupied by thesolid pole extensions 82 f-82 k can be occupied by a mobile poleextension 86, as illustrated.

The method further includes placing the second surface 14 of the pieceof raw steel stock 10B onto the multiple mobile pole extensions 86 andthe solid pole extensions 82, activating the magnetic capabilities ofthe magnetic chuck 74, and milling the first surface 12 of the piece ofraw steel stock 10B to a desired flatness. These actions can beperformed in the manner described above for the piece of the raw steelstock 10. As before, the first surface 12 of the piece of raw steelstock 10B can be milled with the milling element 92 (such as a facemill) that includes a carbide cutting insert 96, including a face millmilling element 92 that includes only one carbide cutting insert 96. Themilling element 92 can mill the first surface 12 of the piece of rawsteel stock 10B until the first surface 12 has an arithmetic meansurface roughness (“Ra”) of 21 micrometers or less. Further, the millingelement 92 can grind the first surface 12 of the piece of raw steelstock 10B to a flat surface within a tolerance of 0.001 inch per 36inches.

The method can further include locating a bow (not illustrated) in thepiece of raw steel stock 10B and arranging an additional solid poleextension 82 between the top surface 76 and where the bow in the pieceof the raw steel stock 10B will be supported for milling. These actionscan be preformed in the manner described above in reference to FIGS. 11and 12 with the bow 98 present in the piece of raw steel stock 10A.

The method can further include removing the piece of raw steel stock 10Bafter the milling of the first surface 12 thereof and repeating theactions describe above to mill the second surface 14 of the piece of rawsteel stock 10B. More particularly, those actions include: determiningwhere on the top surface 76 of the magnetic chuck 74 the first surface12 of the piece of raw steel stock 10B will be supported for milling ofthe second surface 14 thereof; arranging a minimum of four solid poleextensions 82 between the top surface 76 and where the first surface 12of the piece of raw steel stock 10B will be supported for milling of thesecond surface 14 thereof such that the solid pole extensions 82 arerelatively evenly distributed around the area 90 corresponding to theperimeter 48 of the first surface 12 of the piece of raw steel stock 10Band within 2 inches of the perimeter 48 and at least one solid poleextension 82 will be disposed under each of the at least one protrusion116; arranging multiple mobile pole extensions 86 between the topsurface 76 and where the first surface 12 of the piece of raw steelstock 10B will be supported for milling; placing the first surface 12 ofthe piece of raw steel stock 10B onto the multiple mobile poleextensions 86 and the solid pole extensions 82; activating the magneticcapabilities of the magnetic chuck 74; and milling the second surface 14of the piece of raw steel stock 10B to a desired flatness. As before,the second surface 14 can be milled to an arithmetic mean surfaceroughness of 21 micrometers or less and to a flat surface, parallel withthe first surface 12, within a tolerance of 0.001 inch per 36 inches.

Referring to FIG. 17, piece of raw steel stock 10C, which is otherwiseidentical to the piece of raw steel stock 10 of FIG. 1, includes a pairof holes 120 extending through the piece of raw steel stock from thefirst surface 12 through to the second surface 14. The second surface 14of the piece of raw steel stock 10C defines the perimeter 22. The firstsurface 12 defines the perimeter 48. The piece of raw steel stock 10Cincludes the four sides 100, 102, 104, and 106 forming the four corners108, 110, 112, and 114.

Further described herein is a novel method of milling the piece of rawsteel stock 10C stock into a machine-ready piece of steel using themagnetic chuck 74 and a milling element 92. The method includesdetermining where on the top surface 76 of the magnetic chuck 74 thesecond surface 14 of the piece of raw steel stock 10C will be supportedfor milling of the first surface 12 thereof. Referring now to FIG. 18,the area 90 on the top surface of 76 the magnetic chuck 74 correspondingto the perimeter 22 of the second surface 14 of the piece of raw steelstock 10C is identified and determined as where the second surface 14 ofthe piece of raw steel stock 10C will be supported for milling of thefirst surface 12 of the piece of raw steel stock 10C.

The method further includes arranging a minimum of four solid poleextensions 82 l-82 o between the top surface 76 and where the secondsurface 14 of the piece of raw steel stock 10C will be supported formilling of the first surface 12 thereof such that the solid poleextensions 82 l-82 o will be relatively evenly distributed under aperimeter 22 of the second surface 14 of the piece of raw steel stock10C and within 2 inches of the perimeter 22 and at least one solid poleextension 82 p will be disposed between the at least two holes 120.Referring now to FIG. 19, the area 90 of the top surface 76 of themagnetic chuck 74 corresponding to the perimeter 22 of the secondsurface 14 of the piece of raw steel stock 10C is illustrated. Foursolid pole extensions 82 l-82 o are placed on top surface segments 80m-80 p respectively of the magnetic chuck 74. The four solid poleextensions 82 l-82 o are placed at the top surface segments 80 m-80 pthat overlap with the perimeter 22 of the second surface 14 of the pieceof the raw steel stock 10C. The four solid pole extensions 82 l-82 o arerelatively evenly distributed around area 90 to support the perimeter 22of the second surface 14 of the piece of the raw steel stock 10C, withsolid pole extensions 82 l-82 o being placed at top surface segments 80m-80 p of the magnetic chuck 74 to support the corners 108, 110, 112,and 114 of the piece of raw steel stock 10B. A Solid pole extension 82 pis additionally placed at top surface segment 80 q of the magnetic chuck74 to support the second surface 14 of the piece of raw steel stock 10Cbetween the two holes 120. The piece of raw steel stock 10C is moresusceptible to bowing between the holes 120, and the solid poleextension 82 p helps counteract this susceptibility.

The method further includes arranging multiple mobile pole extensions 86between the top surface 76 and where the second surface 14 of the pieceof raw steel stock 10C will be supported for milling. Referring now toFIG. 20, mobile pole extensions 86 are positioned on top surfacesegments 80 of the magnetic chuck 74 within the area 90 and not occupiedby solid pole extensions 82 l-82 p. The area 90 of the top surface 76 ofthe magnetic chuck 74 corresponding to where the perimeter 22 of thesecond surface 14 of the piece of raw steel stock 10C is illustrated.Every top surface segment 80 within the area 90 that is not occupied bysolid pole extensions 82 and 82 l-82 p can be occupied by a mobile poleextension 86, as illustrated.

The method further includes placing the second surface 14 of the pieceof raw steel stock 10C onto the multiple mobile pole extensions 86 andthe solid pole extensions 82 l-82 p, activating the magneticcapabilities of the magnetic chuck 74, and milling the first surface 12of the piece of raw steel stock 10C to a desired flatness. These actionscan be performed in the manner described above for the piece of the rawsteel stock 10 (and 10A, 10B). As before, the first surface 12 of thepiece of raw steel stock 10C can be ground with a milling element 92(such as a face mill) that includes a carbide cutting insert 96,including a face mill milling element 92 that includes only one carbidecutting insert 96. The milling element 92 can mill the first surface 12of the piece of raw steel stock 10C until the first surface 12 has anarithmetic mean surface roughness (“Ra”) of 21 micrometers or less.Further, the milling element 92 can mill the first surface 12 of thepiece of raw steel stock 10C to a flat surface within a tolerance of0.001 inch per 36 inches.

The method can further include locating a bow (not illustrated) in thepiece of raw steel stock 10C and arranging an additional solid poleextension 82 between the top surface 76 and where the bow in the pieceof the raw steel stock 10C will be supported for milling. These actionscan be preformed in the manner described above in reference to FIGS. 11and 12 with a bow 98 present in the piece of raw steel stock 10A.

The method can further include removing the piece of raw steel stock 10Cafter the milling of the first surface 12 thereof and repeating theactions describe above to mill the second surface 14 of the piece of rawsteel stock 10C. More particularly, those actions include: determiningwhere on the top surface 76 of the magnetic chuck 74 the first surface12 of the piece of raw steel stock 10C will be supported for milling ofthe second surface 14 thereof; arranging a minimum of four solid poleextensions 82 between the top surface 76 and where the first surface 12of the piece of raw steel stock 10C will be supported for milling of thesecond surface 14 thereof such that the solid pole extensions 82 arerelatively evenly distributed around the area 90 corresponding to theperimeter 48 of the first surface 12 of the piece of raw steel stock 10Cand within 2 inches of the perimeter 48 and at least one solid poleextension 82 p disposed between the two holes 120; arranging multiplemobile pole extensions 86 between the top surface 76 and where the firstsurface 12 of the piece of raw steel stock 10C will be supported formilling; placing the first surface 12 of the piece of raw steel stock10C onto the multiple mobile pole extensions 86 and the solid poleextensions 82 l-82 p; activating the magnetic capabilities of themagnetic chuck 74; and milling the second surface 14 of the piece of rawsteel stock 10C to a desired flatness. As before, the second surface 14can be milled to an arithmetic mean surface roughness of 21 micrometersor less and to a flat surface, parallel with the first surface 12,within a tolerance of 0.001 inch per 36 inches.

It is to be understood that variations and modifications can be made onthe aforementioned structure without departing from the concepts of thepresent invention, and further it is to be understood that such conceptsare intended to be covered by the following claims unless these claimsby their language expressly state otherwise.

What is claimed is:
 1. A method of milling a piece of raw steel stockdown into to a machine-ready piece of steel comprising: presenting apiece of raw steel stock having a first surface and a second surface onthe opposite side as the first surface, the piece of raw steel stockbeing at least 36 inches wide by 36 inches long and ½ inch thick ormore, and the second surface having a perimeter; presenting a magneticchuck with a top surface configured to support the piece of raw steelstock for milling via magnetic capabilities; determining where on thetop surface of the magnetic chuck the second surface of the piece of rawsteel stock will be supported for milling of the first surface thereof;arranging a minimum of four solid pole extensions on the top surface tosupport the second surface of the piece of raw steel stock for millingof the first surface thereof such that the solid pole extensions will berelatively evenly distributed beneath the perimeter of the secondsurface of the piece of raw steel stock and within 2 inches of theperimeter; locating a bow in the piece of raw steel stock; and arrangingan additional solid pole extension between the top surface and where thebow in the piece of the raw steel stock will be supported for milling;arranging multiple mobile pole extensions on the top surface to supportthe second surface of the piece of raw steel stock for milling, each ofthe multiple mobile pole extensions having a top portion that is biasedaway from the top surface of the magnetic chuck; placing the secondsurface of the piece of raw steel stock onto the top portion of each ofthe multiple mobile pole extensions and the solid pole extensions, suchthat each of the mobile pole extensions and each of the solid poleextensions support the piece of raw steel stock; activating the magneticcapabilities of the magnetic chuck, thus locking the top portion of eachof the multiple mobile pole extensions in place at a position matching acontour of the second surface of the piece of raw steel stock; andmilling the first surface of the piece of raw steel stock to a desiredflatness.
 2. The method of claim 1, wherein, milling the first surfaceof the piece of raw steel stock includes milling with a face millincluding a carbide cutting insert.
 3. The method of claim 1, wherein,milling the first surface of the piece of raw steel stock includesmilling with a face mill, and the face mill includes only one cuttinginsert.
 4. The method of claim 1, wherein, milling the first surface ofthe piece of raw steel stock includes milling the first surface untilthe first surface has an arithmetic mean surface roughness of 21micrometers or less.
 5. The method of claim 1, wherein, milling thefirst surface of the piece of raw steel stock further includes millingthe first surface of the piece of raw steel stock to a flat surfacewithin a tolerance of 0.001 inch per 36 inches.
 6. The method of claim 1further comprising: removing the piece of raw steel stock after themilling of the first surface thereof; determining where on the topsurface of the magnetic chuck the first surface of the piece of rawsteel stock will be supported for milling of the second surface thereof;arranging a minimum of four solid pole extensions on the top surface tosupport the first surface of the piece of raw steel stock for milling ofthe second surface thereof such that the solid pole extensions arerelatively evenly distributed under a perimeter of the first surface ofthe piece of raw steel stock and within 2 inches of the perimeter;arranging multiple mobile pole extensions on the top surface to supportthe first surface of the piece of raw steel stock for milling of thesecond surface thereof, each of the multiple mobile pole extensionshaving a top portion that is biased away from the top surface of themagnetic chuck; placing the first surface of the piece of raw steelstock onto the top portion of each of the multiple mobile poleextensions and the solid pole extensions, such that each of the mobilepole extensions and each of the solid pole extensions support the pieceof raw steel stock; activating the magnetic capabilities of the magneticchuck, thus locking the top portion of each of the multiple mobile poleextensions in place at a position matching a contour of the firstsurface of the piece of raw steel stock; and milling the second surfaceof the piece of raw steel stock to a desired flatness; wherein, millingthe second surface of the piece of raw steel stock includes milling thesecond surface until the second surface has an arithmetic mean surfaceroughness of 21 micrometers or less; and wherein, milling the secondsurface of the piece of raw steel stock further includes milling thesecond surface of the piece of raw steel stock to a flat surface withina tolerance of 0.001 inch per 36 inches.
 7. A method of milling a pieceof raw steel stock into to a machine-ready piece of steel comprising:presenting a piece of raw steel stock having a first surface, a secondsurface on the opposite side as the first surface, and at least oneprotrusion at least 5 inches in length; presenting a magnetic chuck witha top surface configured to support the piece of raw steel stock formilling via magnetic capabilities; determining where on the top surfaceof the magnetic chuck the second surface of the piece of raw steel stockwill be supported for milling of the first surface thereof; arranging aminimum of four solid pole extensions on the top surface to support thesecond surface of the piece of raw steel stock for milling of the firstsurface thereof such that the solid pole extensions are relativelyevenly distributed under a perimeter of the piece of raw steel stock andwithin 2 inches of the perimeter and at least one solid pole extensionwill be disposed under each protrusion; before milling the firstsurface: locating a bow in the piece of raw steel stock; and arrangingan additional solid pole extension between the top surface and where thebow in the piece of the raw steel stock will be supported for milling;arranging multiple mobile pole extensions on the top surface to supportthe second surface of the piece of raw steel stock for milling, each ofthe multiple mobile pole extensions having a top portion that is biasedaway from the top surface of the magnetic chuck; placing the secondsurface of the piece of raw steel stock onto the top portion of each ofthe multiple mobile pole extensions and the solid pole extensions, suchthat each of the mobile pole extensions and each of the solid poleextensions support the piece of raw steel stock; activating the magneticcapabilities of the magnetic chuck, thus locking the top portion of eachof the multiple mobile pole extensions in place at a position matching acontour of the second surface of the piece of raw steel stock; andmilling the first surface of the piece of raw steel stock to a desiredflatness.
 8. The method of claim 7, wherein, milling the first surfaceof the piece of raw steel stock includes milling with a face millincluding a carbide insert.
 9. The method of claim 7, wherein, millingthe first surface of the piece of raw steel stock includes milling witha face mill, and the face mill includes only one cutting insert.
 10. Themethod of claim 7, wherein, milling the first surface of the piece ofraw steel stock includes milling the first surface until the firstsurface has an arithmetic mean surface roughness of 21 micrometers orless.
 11. The method of claim 7, wherein, milling the first surface ofthe piece of raw steel stock further includes milling the first surfaceof the piece of raw steel stock to a flat surface within a tolerance of0.001 inch per 36 inches.
 12. The method of claim 7 further comprising:removing the piece of raw steel stock after the milling of the firstsurface thereof; determining where on the top surface of the magneticchuck the first surface of the piece of raw steel stock will besupported for milling of the second surface thereof; arranging a minimumof four solid pole extensions on the top surface to support the firstsurface of the piece of raw steel stock for milling of the secondsurface thereof such that the solid pole extensions are relativelyevenly distributed under the perimeter of the piece of raw steel stockand within 2 inches of the perimeter and within 2 inches of theperimeter and at least one solid pole extension will be disposed undereach protrusion; arranging multiple mobile pole extensions on the topsurface to support the first surface of the piece of raw steel stock formilling of the second surface thereof, each of the multiple mobile poleextensions having a top portion that is biased away from the top surfaceof the magnetic chuck; placing the first surface of the piece of rawsteel stock onto the top portion of each of the multiple mobile poleextensions and the solid pole extensions, such that each of the mobilepole extensions and each of the solid pole extensions support the pieceof raw steel stock; activating the magnetic capabilities of the magneticchuck, thus locking the top portion of each of the multiple mobile poleextensions in place at a position matching a contour of the firstsurface of the piece of raw steel stock; and milling the second surfaceof the piece of raw steel stock to a desired flatness; wherein, millingthe second surface of the piece of raw steel stock includes milling thesecond surface until the second surface has an arithmetic mean surfaceroughness of 21 micrometers or less; and wherein, milling the secondsurface of the piece of raw steel stock further includes milling thesecond surface of the piece of raw steel stock to a flat surface withina tolerance of 0.001 inch per 36 inches.
 13. A method of milling a pieceof raw steel stock down into to a machine-ready piece of steelcomprising: presenting a piece of raw steel stock having a firstsurface, a second surface on the opposite side as the first surface, andat least two holes extending from the first surface through to thesecond surface; presenting a magnetic chuck with a top surfaceconfigured to support the piece of raw steel stock for milling viamagnetic capabilities; determining where on the top surface of themagnetic chuck the second surface of the piece of raw steel stock willbe supported for milling of the first surface thereof; arranging aminimum of four solid pole extensions on the top surface to support thesecond surface of the piece of raw steel stock for milling of the firstsurface thereof such that the solid pole extensions will be relativelyevenly distributed under a perimeter of the piece of raw steel stock andwithin 2 inches of the perimeter and at least one solid pole extensionwill be disposed between the at least two holes; before milling thefirst surface: locating a bow in the piece of raw steel stock; andarranging an additional solid pole extension between the top surface andwhere the bow in the piece of the raw steel stock will be supported formilling; arranging multiple mobile pole extensions on the top surface tosupport the second surface of the piece of raw steel stock for millingthe first surface thereof, each of the multiple mobile pole extensionshaving a top portion that is biased away from the top surface of themagnetic chuck; placing the second surface of the piece of raw steelstock onto the top portion of each of the multiple mobile poleextensions and the solid pole extensions, such that each of the mobilepole extensions and each of the solid pole extensions support the pieceof raw steel stock; activating the magnetic capabilities of the magneticchuck, thus locking the top portion of each of the multiple mobile poleextensions in place at a position matching a contour of the secondsurface of the piece of raw steel stock; and milling the first surfaceof the piece of raw steel stock to a desired flatness.
 14. The method ofclaim 13, wherein, milling the first surface of the piece of raw steelstock includes milling with a face mill including a carbide insert. 15.The method of claim 13, wherein, milling the first surface of the pieceof raw steel stock includes milling with a face mill, and the face millincludes only one cutting insert.
 16. The method of claim 13, wherein,milling the first surface of the piece of raw steel stock includesmilling the first surface until the first surface has an arithmetic meansurface roughness of 21 micrometers or less.
 17. The method of claim 13,wherein, milling the first surface of the piece of raw steel stockfurther includes milling the first surface of the piece of raw steelstock to a flat surface within a tolerance of 0.001 inch per 36 inches.